From Concept to Installation: The Custom Metal Fabrication Process Explained – Featuring the TWA Hotel and Museum Project at JFK Airport

The TWA Hotel and Museum project perfectly demonstrates how the custom metal fabrication process combines creativity, craftsmanship, and engineering to transform design concepts into physical masterpieces. At MNR Custom Metal, we follow a precise process that delivers high-end, architectural-grade metalwork with excellence.

1. Initial Design Concept and Collaboration

Every custom metal project starts with a concept. For the TWA Hotel and Museum, the design challenge involved honoring the building’s rich mid-century heritage while incorporating modern fabrication techniques and materials.

We collaborated closely with architects, designers, and project managers to understand the aesthetic vision, technical requirements, and material preferences. During this phase, our team reviewed design drawings, material samples, and project specifications to prepare for the next stage.

2. Detailed Engineering and Shop Drawings

Once the team approved the concept, our engineers translated the designs into precise shop drawings. They carefully detailed every measurement, angle, and finish to ensure seamless fabrication and installation later.

For the TWA Hotel, we meticulously planned complex architectural metal elements that needed to blend perfectly with the restored historic building, including decorative panels, trims, and feature pieces inspired by 1960s design.

3. Material Selection and Procurement

Choosing the right materials ensures both performance and aesthetics. For the TWA project, we selected high-quality stainless steel, brass, and aluminum to achieve the desired vintage yet luxurious look while ensuring durability in a high-traffic public space.

Our sourcing process guarantees that every material meets industry standards and project specifications before fabrication begins.

4. Fabrication and Finishing

With finalized drawings and materials ready, our craftsmen began fabrication in our workshop. They used state-of-the-art equipment for cutting, welding, forming, and assembling the metal components.

Our team paid close attention to detail, especially when working on TWA’s intricate metal elements that required custom finishes. We applied specialized techniques like polishing, patination, and protective coatings to achieve the perfect visual effect and long-lasting durability.

5. Quality Control and Pre-Installation Review

Before shipping any piece, we conducted strict quality control inspections. We verified dimensions, finishes, and overall craftsmanship to match the original design and engineering specifications.

For the TWA Hotel, our team pre-fitted and checked every metal piece to ensure flawless installation on-site, preventing costly delays or adjustments.

6. Delivery and Installation

Our final stage involves seamless delivery and professional installation. For a landmark project like the TWA Hotel and Museum, we coordinated closely with other trades and worked carefully around the restored architecture.

Our installation team aligned every piece perfectly, preserving the design integrity and historical significance of the space.

Conclusion

The TWA Hotel and Museum project showcases the precision, collaboration, and craftsmanship required in custom metal fabrication. From concept to installation, MNR Custom Metal executes every detail to perfection, helping bring architectural visions to life.

Whether restoring an iconic landmark or creating custom features for modern luxury spaces, our process delivers quality metalwork designed to last.